Base conducting layer beneath graphite layer of ceramic cathode for use with cathodic arc deposition

ABSTRACT

Cathode structures are disclosed for use with pulsed cathodic arc deposition systems for forming diamond-like carbon (DLC) films on devices, such as on the sliders of hard disk drives. In illustrative examples, a base layer composed of an electrically- and thermally-conducting material is provided between the ceramic substrate of the cathode and a graphitic paint outer coating, where the base layer is a silver-filled coating that adheres to the ceramic rod and the graphitic paint. The base layer is provided, in some examples, to achieve and maintain a relatively low resistance (and hence a relatively high conductivity) within the cathode structure during pulsed arc deposition to avoid issues that can result from a loss of conductivity within the graphitic paint over time as deposition proceeds. Examples of suitable base material compounds are described herein where, e.g., the base layer can withstand temperatures of 1700° F. (927° C.).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/583,121, filed Sep. 25, 2019, having Attorney Docket No. WDT-1344(WDA-4451-US), entitled “BASE CONDUCTING LAYER BENEATH GRAPHITE LAYER OFCERAMIC CATHODE FOR USE WITH CATHODIC ARC DEPOSITION,” the entirecontent of which is incorporated herein by reference.

FIELD

The disclosure relates, in some embodiments, to cathodes for use withpulsed cathodic arc deposition. More specifically, but not exclusively,the disclosure relates to ceramic cathodes for forming diamond-likecarbon films on devices such as the sliders of hard disk drives.

INTRODUCTION

Pulses cathodic arc deposition is a type of physical vapor deposition inwhich an electric arc vaporizes material such as graphite that is coatedon a cathode structure. The vaporized material propagates to andcondenses on a device or substrate to form a thin film. One type of filmthat can be formed via cathodic arc deposition is a diamond-like carbon(DLC) film, which may be formed, for example, on the sliders of harddisk drives (HDDs) or on other devices that benefit from an extremelyhard and durable protective film or coating. It would be desirable toprovide improved methods and apparatus for cathodic arc deposition forforming DLC films or other films or coatings.

SUMMARY

The following presents a simplified summary of some aspects of thedisclosure to provide a basic understanding of such aspects. Thissummary is not an extensive overview of all contemplated features of thedisclosure, and is intended neither to identify key or critical elementsof all aspects of the disclosure nor to delineate the scope of any orall aspects of the disclosure. Its sole purpose is to present variousconcepts of some aspects of the disclosure in a simplified form as aprelude to the more detailed description that is presented later.

One embodiment of this disclosure provides a cathode structure for usein a deposition system, the cathode structure comprising: a ceramicstructure; a first layer formed on the ceramic structure and comprisingan electrically-conducting material that adheres to the ceramicstructure; and a second layer formed on the first layer and comprisingcarbon.

Another embodiment of the disclosure provides a method for forming afilm, the method comprising: passing an electrical current through aceramic structure; passing the electrical current through a base layerformed on the ceramic structure and comprised of anelectrically-conducting material that adheres to the ceramic structure;and passing the electrical current through an outer layer formed on thebase layer and comprised of carbon to cause at least some of the carbonto be transferred to a device to form a film on the device.

Yet another embodiment of the disclosure includes a deposition apparatuscomprising: an anode; a cathode comprising a ceramic structure, a firstlayer formed on the ceramic structure and comprised of anelectrically-conducting material that adheres to the ceramic structure,and a second layer formed on the first layer and comprised of carbon; apower supply coupled to the cathode and configured to cause the cathodeto generate a plasma that includes carbon particles; an electrode onwhich a device to receive a carbon film is mounted; a pulse generatorconnected with the electrode to apply a bias pulse; and a controllerconfigured to control the power supply and the pulse generator.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary cathode structure for use in a pulsedcathodic arc deposition system or apparatus where the cathode structureincludes a base conducting layer.

FIG. 2 illustrates exemplary rod-shaped cathodes, including a bareceramic cathode and a ceramic cathode with a base conducting layer andan outer graphitic paint layer coated thereon.

FIG. 3 illustrates a cross-section of a distal end of the exemplaryrod-shaped cathode of FIG. 2 with the cross-section taken perpendicularto a long axis of the cathode.

FIG. 4 illustrates a longitudinal cross-section of one side of thedistal end of the exemplary rod-shaped cathode of FIG. 2 with thecross-section taken parallel to the long axis.

FIG. 5 is a flow chart summarizing an exemplary method or procedure forcoating and baking a ceramic cathode, such as the cathodes of FIGS. 1-4.

FIG. 6 illustrates an exemplary a disk drive having a slider on which adiamond like carbon (DLC) film may be deposited by a deposition systemusing the cathodes of FIGS. 1-4.

FIG. 7 illustrates an exemplary assembly of components for use within adisk drive that includes a slider on which a DLC film may be depositedusing the cathodes of FIGS. 1-4.

FIG. 8 illustrates an exemplary cathode structure for use in adeposition apparatus.

FIG. 9 illustrates another exemplary cathode structure for use in adeposition apparatus.

FIG. 10 illustrates yet another exemplary cathode structure for use in adeposition apparatus.

FIG. 11 is a flow chart summarizing an exemplary method or procedure forforming a film or coating.

FIG. 12 is a flow chart summarizing another exemplary method orprocedure for forming a film or coating.

FIG. 13 is a flow chart summarizing another exemplary method orprocedure for forming a film or coating.

FIG. 14 is a block diagram illustrating an exemplary depositionapparatus having a cathode structure as in FIG. 8.

FIG. 15 illustrates an exemplary cathode structure where the cathodestructure includes an electrically-conducting base layer and a carbonlayer.

FIG. 16 illustrates a rod-shaped cathode structure with anelectrically-conducting base layer and a carbon layer.

FIG. 17 illustrates a cross-section of a distal end of the exemplaryrod-shaped cathode structure of FIG. 16 with the cross-section takenperpendicular to a long axis of the cathode.

FIG. 18 illustrates a longitudinal cross-section of one side of thedistal end of the exemplary cathode structure of FIG. 16 with thecross-section taken parallel to the long axis.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part thereof. In addition to theillustrative aspects, embodiments, and features described above, furtheraspects, embodiments, and features will become apparent by reference tothe drawings and the following detailed description. The description ofelements in each figure may refer to elements of proceeding figures.Like numbers may refer to like elements in the figures, includingalternate embodiments of like elements.

Aspects described herein are directed to cathodic arc depositionstructures, methods and apparatus. In at least some cathodic arcdeposition systems, particularly pulses cathodic arc systems, aconducting path between a ceramic cathode rod and the anode of thesystem is via a thin layer of graphite coated onto the ceramic rod,which may be, e.g., a graphite-filled paint or graphitic paint. In use,carbon is emitted from the graphite coating and deposited on a device toform a DLC film on the device (which may be, for example, the slider ofa HDD). The graphite coating of the cathode rod can be affected by thearc pulsing process and, for example, can lose conductivity over timeand cause the deposition process to become unstable, which might resultin unsatisfactory DLC films. In particular, a loss of conductivity canresult in a poor quality carbon plume during deposition, which in turnmay result in a degradation of the properties of the DLC film and/or aloss of uniformity in the DLC film thickness. If satisfactoryconductivity is not maintained, the deposition process may need to besuspended so that no unsatisfactory DLC films are formed, with thedeposition process then restarted once a new cathode rod has beeninstalled. If the problem is not detected before the DLC films areformed, the devices upon which the films are deposited may need to bediscarded. Attempts to remedy these problems by modifying the graphitecoating and/or the manner by which it is applied to the cathode rodhave, thus far, been largely unsuccessful and so a different solution isdisclosed and described herein.

Herein structures, methods and apparatus are disclosed where, e.g., alayer of electrically-conducting material is provided between theceramic cathode rod and the graphite coating, where theelectrically-conducting material is formed of a material such as asilver-containing (or silver-filled) coating that adheres to the ceramicrod (permanently or at least for a sufficiently long time for practicalpurposes). (By a silver-containing or silver-filled coating, it is meantthat the coating includes at least some silver among its otherconstituents, such as an amount of silver in the range of 10% to 90% ofthe coating, e.g. 10%, 50%, 75%, etc. For a particular application, asuitable or efficacious percentage of the silver can be determined viaotherwise routine testing to achieve target electrical and/or thermalcharacteristics, such as a target conductivity. Particular examples aredescribed below.) The electrically-conducting material is alsothermally-conducting. This coating is referred to herein as a “base”coating or layer because it is formed or applied below the graphitelayer and forms a base for that layer. The base conducting layer mayalso be referred to as an “intermediate” coating or layer since it isintermediate between the ceramic of the cathode rod and the graphitecoating (which may be painted onto or coated over the base layer to forman over layer). The combination of the base coating and the graphitecoating may be referred to as a two-layer coating, a dual-layer coating,or a multiple layer coating or other suitable terms.

FIG. 1 illustrates an exemplary cathode structure 100 that includes asilver-containing base electrically-conducting layer or coating 102between a ceramic substrate 104 of the cathode and a graphitic paint106. In implementations where the ceramic substrate of the cathode is inthe shape of a tube, the ceramic substrate itself and the layers coatedthereon may be curved and the silver-containing base layer 102 and thegraphitic paint 106 may be applied to coat both the outer surface of adistal end of the ceramic and an inner surface of the distal end of theceramic (as shown in FIG. 2, discussed below). The silver-containingbase conducting layer 102 is employed, at least in part, to provide amore consistent and stable conductivity path between the anode andceramic rod of the cathode. This, in turn, can yield a more stablearcing process over the course of one or more cathode rod life cycles.That is, in use, the silver-containing base conducting layer provides asubstantially uniform, stable, and consistent conductive path for thearcing process to avoid or mitigate the loss of conductively problemsdiscussed above. The silver-containing base conducting layer may bereferred to as conductivity-path enhancement coating or layer, middlelayer, intervening layer, buffer layer, an intermediate or intermediarycoating or layer, or by any other suitable terms. Silver is just oneexample of a conducting material that may be used in the base conductinglayer. Other examples are discussed below where the material may be, forexample, nickel, copper or gold.

In some illustrative examples described herein, the silver-containingbase conducting layer is a high temperature-tolerant electrically andthermally conductive silver flake coating. By high temperature-tolerant,it is meant that the material tolerates high temperatures, such astemperatures greater than 500° F. without significant loss of itsadherent and conductivity properties. In some examples, thesilver-containing base conducting layer is an adhesive or coating formedof materials that can withstand 1700° F. (927° C.), which issubstantially higher than the temperatures often used during cathodicarcing to form DLC films (which are often less than 500° F.). Oneparticular example of a suitable high temperature-tolerantsilver-containing base coating is the Pyro-Duct™ 597-C coating providedby Aremco Products, Inc. (where Pyro-Duct™ is a trademark of AremcoProducts, Inc.). Pyro-Duct™ 597-C is composed of high purity silverflake with a D50 particle size of less than twenty microns and thematerial has a volume resistivity of about 0.0002 ohm-cm at roomtemperature. (Particle Size Distribution D50 is also known as the mediandiameter or medium value of the particle size distribution, that is, itis the value of the particle diameter at 50% in the cumulativedistribution.) All constituents of Pyro-Duct™ 597-C are electrically andthermally conductive. It may be applied, for example, by dipping,brushing or with a spray gun.

The silver-containing coating may be applied using the same or similartechniques used to apply the graphitic paint conducting layer 106 with abaking process used for curing the layers, as described below. Theillustrative coating material (Pyro-Duct™ 597-C) is a water baseadhesion/coating, which has been found to provide excellent adhesion toceramic cathode rods formed of aluminum oxide (Al₂O₃) or beryllium oxide(BeO, also called beryllia). The thickness of the base coating may beselected or adjusted to achieve a selected or desired conductivity.

Exemplary Cathode Rod with Base Coating

FIG. 2 illustrates a bare or uncoated ceramic cathode tube or rod 200formed of a ceramic material 201 and having an open distal end 202 and asimilar ceramic cathode tube or rod 204 on which a two-layer coating 206has been applied to its open distal end 208, where the two-layer coating206 includes the aforementioned outer graphitic paint layer and thesilver-containing base conductive layer. It is noted that, in thefigure, the silver-containing base conductive layer of two-layer coating206 is obscured from view because it is beneath the graphitic paint(which is shown using a diagonal hatch pattern). It is also noted thatboth the inner and outer surfaces of the open distal end 208 of theceramic tube 204 are coated with the two-layer coating 206.

FIG. 3 is a cross-sectional illustration of a slice of the distal end ofan exemplary cathode rod or tube 300 having a ceramic substrate 302shaped in the form of a tube or cylinder, with the cross-section takenthrough the distal end and perpendicular to a long axis of the tube. Athin silver-containing base conducting layer 304 (shown using a squarecross-hatch pattern) is formed or coated onto both the inner and outersurfaces of the open distal end of the ceramic substrate 302. Agraphitic paint layer 306 (shown again using a diagonal hatch pattern)is formed or coated onto the conducting layer 304. (As shown in FIG. 4,discussed below, the graphitic paint layer and the silver-containingbase conducting layer may extend around the distal terminus of the tubeto form continuous coatings.) Note that the illustration of FIG. 3 isnot to scale.

In implementations where the cathode rod 300 is used in cathodic arcdeposition, the ceramic substrate 302 is often much thicker than thegraphitic paint layer 306, which, in turn, is often much thicker thanthe silver-containing base conducting layer 304. In some examples, thethickness of the various components and layers are: the ceramicsubstrate 302 thickness is in the range of 2.7 mm to 2.8 mm; thesilver-containing base conducting layer 304 thickness is in the range of0.015 mm to 0.02 mm; the graphitic paint layer 306 thickness is in therange of 0/02 mm to 0.03 mm. Note also that to allow one to more easilydistinguish the various components and layers in FIG. 3, the graphiticpaint layer 306 is shaded dark gray, the silver-containing base layer304 is shaded as a lighter gray, and the ceramic substrate 302 is shadedusing a still lighter gray. The hues shown in the figure do notnecessarily correspond to the actual colors of the components in apractical device.

FIG. 4 is a cross-sectional illustration of one end portion of thedistal end an exemplary cathode rod or tube 400 such as one configuredas in FIG. 2, with the cross-section taken parallel with a long axis ofthe tube. As shown, the silver-containing base conductive layer 404(shown again using a square cross-hatch pattern) and the graphitic paintlayer 406 (shown again using a diagonal hatch pattern) extend around adistal end of the ceramic substrate 402. Note that FIG. 4 shows a crosssection through only one portion of the distal end of cylindricalceramic tube. The diametrically opposite portion is not shown in FIG. 4but has the same components and layers. The illustration of FIG. 4 isnot to scale.

Exemplary Application and Curing Process

FIG. 5 is a flow diagram illustrating an exemplary method or procedure500 for coating and baking a ceramic cathode, such as the coatedcathodes shown in FIGS. 1-4, or other substrates. At block 502, atechnician or a suitably-programmed apparatus applies asilver-containing electrically conductive coating to a substrate, suchas to the distal end of a cylindrical ceramic cathode rod or tube formedof BeO or Al₂O₃. The silver-containing electrically conductive coatingmay be painted onto the cathode or applied using any suitableapplication technique. In some examples, the silver-containingelectrically conductive coating is the Pyro-Duct™ 597-C coating notedabove. At block 504, a suitable oven or other heating system is used tobake the cathode with the silver-containing coating at about 200° F. (orabout 94° C.) for at least two hours to achieve a contact resistance ofabout 10 ohms. The baking procedure of block 504 may be regarded as afirst baking stage. At block 506, the technician or thesuitably-programmed apparatus applies a graphitic paint to the bakedsilver-containing coating, which may be achieved by painting thegraphitic material onto the silver-containing coating or by using anyother suitable method of application, such as dipping the distal end ofthe cathode into a vessel containing the graphitic paint in fluid form.

At block 508, a suitable oven or other heating system is used to bakethe cathode with the silver-containing coating and graphitic paint atabout 320° F. (or about 160° C.) for about forty-eight hours. This isconsiderably longer than some alternative baking procedures that mightinstead bake the graphitic paint for only one to four hours. The processof FIG. 5 also uses a somewhat lower baking temperature than somealternative baking procedures that might instead bake at 260° C. Thebaking procedure of block 508 may be regarded as a second baking stage.At block 510, the oven is used to bake the cathode with thesilver-containing coating and graphitic paint at about 446° F. (or about230° C.) for about another two hours to achieve a contact resistance inthe range of 10-50 ohms (depending on coating thickness). The bakingprocedure of block 504 may be regarded as a third baking stage. As notedabove, the exemplary silver-containing coating material (Pyro-Duct™597-C) can withstand up to 1700° F. (927° C.) and so it can easilywithstand the 446° F. of the third baking stage. If a differentconducting material is used as the base coating layer, care should betaken to choose a material that can withstand a high baking temperature(as may be useful to achieve a particular desired or target electricalresistance). A particular example of a suitable graphitic paint is PartNo: SPI#05006-AB provided by Structure Probe, Inc. (SPI) of WestChester, Pa. For practical purposes, it is often desirable to achieveand maintain a relatively low contact resistance (and hence a relativelyhigh conductivity) within the distal end coating of the cathode used forpulsed arc deposition. This is to avoid the issues discussed above thatcan result from a loss of conductivity within the coating. For example,it may be desirable to achieve and maintain a contact resistance below300 ohms over hundreds of thousands of pulse cycles. In some examples, atest cathode coated and baked using the procedure of FIG. 5 (withPyro-Duct™ 597-C as the silver-containing base layer beneath a layer ofgraphitic paint) was found to maintain a contact resistance of less than300 ohms for over 140,000 pulses. In contrast, a test cathode using thesame graphitic paint (baked at two hours at about 260° C.) but withoutthe silver-containing base coating was found to reach 300 ohms afterless than 50,000 pulses. As discussed above, a loss of conductivity mayrequire suspending the deposition procedure and then restarting theprocedure with a new cathode. And so maintaining satisfactoryconductivity over a long pulse count lifetime is beneficial. It shouldbe noted that the actual contact resistance values may depend on thethickness and uniformity of the various coatings and the particularlocations on the cathode where contact resistance is measured, as wellas on the particular ceramic material of the cathode. In some testcathodes, BeO was found to result in lower contact resistance valuesthan Al₂O₃. Generally speaking, baked coatings can provide lowerresistance values than non-baked coatings. Also, generally speaking, itis noted that the highly resistive top graphite coating layer used aspart of the cathode during deposition operates to “mask” the underlyingsilver paint layer to prevent it from “seeing” the arcing and causingcontamination in resulting DLC films.

Cathodes of the type formed as described herein may be used in a varietyof different pulsed cathodic arc deposition machines or other depositionsystems, machines or apparatus. In some particular examples, the cathodeis used within the NEXUS DLC-X Diamond-Like Carbon System of VeecoInstruments Inc. or other systems of devices of Veeco Instruments Inc.

Other metals that may be appropriate for use in the base layer of thecathode include copper, gold, and nickel, or combinations thereof, orother transition metals that have sufficiently high melting points andappropriate conductance values. For example, depending upon theparticular metal, flakes or particles of the metal may be suspended ormixed within a suitable coating or adhesive compound. Otherwise routineexperimentation may be performed to identify combinations of metals andsuspension compounds that together achieve and maintain sufficientconductivity and sufficient adherence to the ceramic substrate and tothe graphite overlayer to withstand the temperatures needed for use withparticular deposition systems. Otherwise routine experimentation may beused to identify particular baking temperatures and durations forselected combinations of compounds and metals. The exemplarytemperatures and durations of FIG. 5 have been found to be satisfactoryfor use with Pyro-Duct™ 597-C to form a cathode for use with the NEXUSDLC-X Diamond-Like Carbon System of Veeco Instruments Inc. Othercompounds that may be satisfactory for use as the base layer on thecathode within at a least some deposition systems and methods include:Pyro-Duct™ 598-A (which is a nickel-filled adhesive) and 598-C (which isa nickel-filled coating). Other compounds from other companies may besatisfactory as well, and the Aremco Products, Inc. products identifiedherein are merely exemplary.

Exemplary Slider for Storage Device with DLC Coating

A DLC film may be coated onto components or devices of an HDD and, forthe sake of completeness, a brief description will now be provided of anexemplary HDD that has a slider where at least one surface of the slideris coated in a DLC film formed using a pulsed cathodic arc depositionprocess having a cathode configured as described above. The particularexample of an HDD configured for heat assisted magnetic recording(HAMR), but DLC films may be used in other HDD designs with otherrecording technologies and a slider is just one component of an HDDcomponent that may have a DLC film coating. Hence, the following ismerely illustrative and not limiting.

FIG. 6 illustrates a disk drive 600 configured for HAMR. The disk drive600 includes one or more media 602, a spindle assembly 604, a drivehousing 606, a slider 608 and control circuitry 610. The slider 608 mayinclude a slider head 612 (shown in dashed lines as it is formed on theunderside of the distal end of the slider 608. The slider 608 may beused to position a laser (not shown in FIG. 6). The one or more media602 may be configured to store data. The media 602 may be a magneticrecording medium, such as a HAMR medium, in the form of a disk, or anyother suitable means for storing data. The media 602 is positioned onthe spindle assembly 604 that is mounted to the drive housing 606. Datamay be stored along tracks in the magnetic recording layer of the media602. The reading and writing of data are accomplished with a readelement and a write element located with the slider 608. The writeelement is used to alter the properties of the magnetic recording layerof the media 602 and thereby write information thereto. In someimplementations, the slider 608 may include an inductive read/write heador a Hall Effect head. During operation of the disk drive 600, a spindlemotor (not shown) rotates the spindle assembly 604, and thereby rotatesthe media 602. The slider 608 and the laser (not shown) may bepositioned over the media 602 at a particular location along a desireddisk track, such as track 607 shown in dashed lines. The positions ofthe slider 608 and the laser relative to the media 602 may be controlledby the control circuitry 610.

FIG. 7 illustrates a side view of an exemplary assembly 700 thatincludes a slider 702 and a HAMR medium 704 where a bottom surface 705of the slider 702 includes a DLC coating 706 formed using a pulsedcathodic arc deposition process having a cathode configured as describedabove. In the example of FIG. 7, the DLC coating 706 extends over onlyone exemplary portion of the bottom surface 705 of the slider 702 but,additionally or alternatively, other portions of the slider (or othercomponents of assembly 700) may have DLC coatings or films as well. TheDLC coating 706 is not shown to scale. The assembly 700 also includes asub-mount 708, a laser 710, a waveguide 712, a near-field transducer(NFT) 714, a writer 716 and a reader 718. The assembly 700 is positionedover the HAMR media 704. The slider 702 may be one component or severalcomponents. For example, the slider 702 may include a slider and aslider head (not separately shown). In some implementations, the sliderhead may be a separate component mounted to the slider 702. In someexamples, the DLC coating 706 may be formed on the slider head. Thesub-mount 708, the laser 710, the waveguide 712, the NFT 714, the writer716 and the reader 718 may be implemented in the slider, the slider heador combinations thereof.

The bottom (first) surface 705 of the slider 702 faces the media 704.The bottom surface 705 may be referred to as an air bearing surface(ABS). The slider 702 also includes a top (second) surface 709 thatfaces away from the media 704. The sub-mount 708 is coupled to a topsurface 709. The laser 710 is coupled to the sub-mount 708, and in someexamples, to the slider 702. The waveguide 712, the NFT 714, the writer716 and the reader 718 may be located near or along the ABS 705 of theslider 702. The writer 716 may be configured as a writing element ormeans for writing data on the media 704, and the reader 718 may beconfigured as a reading element or means for reading data on the media704.

The laser 710 is configured to generate and transmit light energy (e.g.,a laser beam) into the waveguide 712, which directs light energy toand/or near the NFT 714, which is near the ABS 705 of the slider 702.Upon receiving and/or being near the light energy, the NFT 714 may causea portion of the media 704 to heat up, and/or the light energy travelingthrough the waveguide may heat a portion of the media 704. For example,upon receiving and/or being near the light energy, the NFT 714 maygenerate localized heat that heats a portion of the media. Thus, thelight energy may travel through the waveguide 712 such that the NFT 714emits heat to a portion of the media 704. In the example of FIG. 7, theDLC coating 706 is positioned so at least a portion of the heat and/orlight energy passes through the DLC coating 706 (which is configured tobe sufficiently thin to permit the portion of heat and/or light energyto pass through it). In other examples, the DLC coating may bepositioned elsewhere on the bottom (ABS) surface 705 of the slider 702.

Additional Exemplary Structures and Methods

FIG. 8 illustrates an exemplary cathode structure 800 that includes aceramic structure 802, a first layer 804 formed on the ceramic structure802 and comprising an electrically-conducting material that adheres tothe ceramic structure, and a second layer 806 formed on the first layerand comprising carbon, such a carbon in the form of graphite. Thecathode structure 800 may be used in a deposition system, such as apuled cathodic arc deposition system.

FIG. 9 illustrates an exemplary cathode structure 900 that includes: aceramic structure 902 formed of beryllium oxide or aluminum oxide orother suitable ceramic material; a base layer 904 formed on the ceramicstructure 902 and composed of a high temperature- tolerant (e.g. >500°F.) electrically-conducting and thermally-conducting metallic (ormetal-filled) coating that permanently (or substantially permanently,e.g. for a sufficiently long time for practical pulsed cathodic arcdeposition purposes) adheres to the ceramic structure, where the metalincludes, e.g., one or more of silver, copper, gold, or nickel orcombinations thereof; and an outer layer 906 formed on the base layerand composed of a graphitic material. (By a metallic or metal-filledcoating, it is meant that the coating includes at least some metal amongits other constituents, such as an amount of metal in the range of 10%to 90% of the coating, e.g., 10%, 50%, 75%, etc. For a particularapplication, a suitable or efficacious percentage of the metal can bedetermined via otherwise routine testing to achieve target electricaland/or thermal characteristics, such as a target conductivity.Particularly examples are disclosed elsewhere herein.) The cathodestructure 900 may be used in a deposition system, such as a pulsedcathodic arc deposition system.

FIG. 10 illustrates an exemplary cathode structure 1000 that includes: aceramic structure 1002; a base layer 1004 formed on the ceramicstructure 1002 and composed of materials selected to withstandcathodic-arc deposition temperatures of at least 500° F. such as asilver-containing coating or adhesive that is tolerant to 1700° F. andcomprises silver flakes with a D50 particle size of less than twentymicrons and having a volume resistivity of about 0.0002 ohm-cm at roomtemperature; and an outer layer 1006 formed on the base layer andcomposed of a graphitic material. The cathode structure 1000 may be usedin a deposition system, such as a pulsed cathodic arc deposition system.As explained above, other types of metallic compounds such as coatingsor adhesives with metal flakes may be used in at least some depositionsystems and methods.

FIG. 11 illustrates an exemplary method or procedure 1100 for forming afilm or coating. At block 1102, a pulsed cathodic arc deposition systemor other suitable deposition apparatus routes an electrical currentthrough a ceramic structure of a cathode. At block 1104, the depositionapparatus routes the electrical current through a base layer formed onthe ceramic structure and comprised of an electrically-conductingmaterial that adheres to the ceramic structure. At block 1106, thedeposition apparatus routes the electrical current through an outerlayer formed on the base layer and comprised of carbon to cause at leastsome carbon to be transferred to a device to form a film on the device.It is noted that, with the cathode structure used in conjunction with aseparate anode, current may be regarded as flowing into the ceramicstructure of the cathode from a current source, then through the baselayer, then through the outer carbon layer and then to the anode(through a plasma). Electrical current flow is in the oppositedirection.

FIG. 12 illustrates an exemplary method or procedure 1200 for forming afilm or coating. At block 1202, a pulsed cathodic arc deposition systemor other suitable deposition apparatus routes an electrical currentthrough a ceramic structure formed of beryllium oxide or aluminum oxideor other suitable ceramic material or compound. At block 1204, thedeposition apparatus routes the electrical current through a base layerformed on the ceramic structure and composed of a hightemperature-tolerant (>500° F.) electrically-conducting andthermally-conducting metallic coating or adhesive (such as a metallicpaint) that permanently (or substantially permanently) adheres to theceramic structure where the metal includes flakes of, e.g., one or moreof silver, copper, gold or nickel or combinations thereof. At block1206, the deposition apparatus routes the electrical current through agraphitic paint layer formed on the base layer to cause at least somecarbon from the graphitic paint to be transferred to a device to form aDLC film or coating on the device. The device may be, for example, theslider of a HDD.

FIG. 13 illustrates an exemplary method or procedure 1300 for forming afilm or coating. At block 1302, a pulsed cathodic arc deposition systemor other suitable deposition apparatus routes an electrical currentthrough a ceramic structure formed of beryllium oxide or aluminum oxideor other suitable ceramic material or compound. At block 1304, thedeposition apparatus routes the electrical current through a base layerformed on the ceramic structure and composed or comprised of materialsselected to withstand cathodic-arc deposition temperatures of at least500° F., such as a silver-containing compound that is tolerant to 1700°F., which includes silver flakes with a D50 particle size of less thantwenty microns and having a volume resistivity of about 0.0002 ohm-cm atroom temperature. At block 1306, the deposition apparatus routes theelectrical current through a graphitic paint layer formed on the baselayer to cause at least some carbon from the graphitic layer to betransferred to a device to form a DLC film or coating on the device. Thedevice may be, for example, the slider of a HDD.

FIG. 14 is a block diagram illustrating an exemplary pulsed cathodic arcdeposition system or apparatus 1400 for forming a film or coating on adevice or substrate. The deposition apparatus 1400 includes an anode1402 and a cathode 1404 having a ceramic structure, a first layer formedon the ceramic structure where the first layer is anelectrically-conducting material that adheres to the ceramic structure,and a second layer formed on the first layer and composed or comprisedof carbon, such as graphite. A power supply 1406 is coupled to the anode1402 and the cathode 1404 and configured to cause the cathode 1404 togenerate a plasma (not shown) that includes carbon particles fordeposition. The deposition apparatus also includes an electrode 1408 onwhich a device or substrate to receive a carbon film or coating ismounted. A pulse generator 1412 is connected to the electrode 1408 toapply one or more bias pulses. A controller 1414 is configured tocontrol the power supply 1406 and the pulse generator 1412 to, forexample, cause the cathode 1404 to generate a plasma that includescarbon particles that are then deposited on the device or substrate 1410in a controlled manner to have desired or selected properties, such asthickness, density, hardness, etc. Note that the block diagram of FIG.14 does not illustrate all components that may be included in a pulsedcathodic arc deposition system or apparatus. For example, magneticcontainment components may be provided to contain the plasma and guidethe carbon particles in a controlled manner to the device or substratefor deposition thereon.

At least some of the components and devices described herein may beconfigured using any suitable means for performing the associatedfunction. By way of example, an apparatus for forming a film mayinclude: a means for passing an electrical current through a ceramicstructure; a means for passing the electrical current through a firstlayer formed on the ceramic structure and comprised of anelectrically-conducting material that adheres to the ceramic structure;and a means for passing the electrical current through a second layerformed on the first layer and comprised of graphite to cause at leastsome carbon from the graphite to be transferred to a substrate to form afilm on the substrate.

Additional Exemplary Cathode Structures with Base Coatings

FIG. 15 illustrates an exemplary cathode structure 1500 that includes anelectrically-conducting base layer or coating 1502 between a ceramicsubstrate 1504 of the cathode and a carbon layer 1506. Theelectrically-conducting base layer 1502 may be, e.g., asilver-containing layer or coating, such as the silver-containing layersor coatings discussed above. The carbon layer 1506 may be, e.g., agraphitic coating, such as the graphitic paint discussed above. Inimplementations where the ceramic substrate 1504 is in the shape of atube or rod, the ceramic substrate and the layers coated thereon may becurved, and the electrically-conducting base layer 1502 and the carbonlayer 1506 may be applied to coat both the outer surface of a distal endof the ceramic and an inner surface of the distal end of the ceramic (asshown in FIG. 16, discussed next).

FIG. 16 illustrates a coated ceramic cathode tube or rod 1600 formed ofa ceramic substrate material 1601 having an open distal end 1602, wherethe coating includes an outer carbon layer 1604 (shown using a diagonalhatch pattern) and an electrically-conducting base layer 1606 (shownusing a square cross hatch pattern). In the figure, a portion of theouter carbon layer 1604 is shown cut open so that a portion of the innerelectrically-conducting base layer 1606 can be seen. This is forillustrative purposes only. It is noted that, in this example, both theinner and outer surfaces of the open distal end 1602 of the ceramic tube1600 are coated with the two-layer coating 1604/1606. The carbon layer1604 may be, e.g., a graphitic coating, such as the graphitic paintdiscussed above. The electrically-conducting base layer 1606 may be,e.g., a silver-containing layer or coating, such as thesilver-containing layers or coatings discussed above.

FIG. 17 is a cross-sectional illustration of a slice of the distal endof an exemplary cathode rod or tube 1700 having a ceramic substrate 1702shaped in the form of a tube or cylinder, with the cross-section takenthrough the distal end and perpendicular to a long axis of the tube. Athin electrically-conducting base layer 1704 (shown using a squarecross-hatch pattern) is formed or coated onto both the inner and outersurfaces of the open distal end of the ceramic substrate 1702. A carbonlayer 1706 (shown again using a diagonal hatch pattern) is formed orcoated onto the conducting layer 1704. The carbon layer 1706 may be,e.g., a graphitic coating, such as the graphitic paint discussed above.The electrically-conducting base layer 1704 may be, e.g., asilver-containing layer or coating, such as the silver-containing layersor coatings discussed above. Note that the illustration of FIG. 17 isnot to scale.

FIG. 18 is a cross-sectional illustration of one end portion of thedistal end an exemplary cathode rod or tube 1800 such as one configuredas in FIG. 18, with the cross-section taken parallel with a long axis ofthe tube. As shown, the electrically-conducting base layer 1804 (shownagain using a square cross-hatch pattern) and the carbon layer 1806(shown again using a diagonal hatch pattern) extend around a distal endof the ceramic substrate 1802. Note that FIG. 18 shows a cross sectionthrough only one portion of the distal end of cylindrical ceramic tube.The diametrically opposite portion is not shown in FIG. 18 but has thesame components and layers. The carbon layer 1806 may be, e.g., agraphitic coating, such as the graphitic paint discussed above. Theelectrically-conducting base layer 1804 may be, e.g., asilver-containing layer or coating, such as the silver-containing layersor coatings discussed above. The illustration of FIG. 18 is not toscale.

The examples set forth herein are provided to illustrate certainconcepts of the disclosure. The apparatus, devices, or componentsillustrated above may be configured to perform one or more of themethods, features, or steps described herein. Those of ordinary skill inthe art will comprehend that these are merely illustrative in nature,and other examples may fall within the scope of the disclosure and theappended claims. Based on the teachings herein those skilled in the artshould appreciate that an aspect disclosed herein may be implementedindependently of any other aspects and that two or more of these aspectsmay be combined in various ways. For example, an apparatus may beimplemented or a method may be practiced using any number of the aspectsset forth herein. In addition, such an apparatus may be implemented orsuch a method may be practiced using other structure, functionality, orstructure and functionality in addition to or other than one or more ofthe aspects set forth herein.

Aspects of the present disclosure have been described above withreference to schematic flowchart diagrams and/or schematic blockdiagrams of methods, apparatus, systems, and computer program productsaccording to embodiments of the disclosure. It will be understood thateach block of the schematic flowchart diagrams and/or schematic blockdiagrams, and combinations of blocks in the schematic flowchart diagramsand/or schematic block diagrams, can be implemented by computer programinstructions. These computer program instructions may be provided to aprocessor of a computer or other programmable data processing apparatusto produce a machine, such that the instructions, which execute via theprocessor or other programmable data processing apparatus, create meansfor implementing the functions and/or acts specified in the schematicflowchart diagrams and/or schematic block diagrams block or blocks.

The subject matter described herein may be implemented in hardware,software, firmware, or any combination thereof. As such, the terms“function,” “module,” and the like as used herein may refer to hardware,which may also include software and/or firmware components, forimplementing the feature being described. In one example implementation,the subject matter described herein may be implemented using a computerreadable or machine readable medium having stored thereon computerexecutable instructions that when executed by a computer (e.g., aprocessor) control the computer to perform the functionality describedherein. Examples of machine readable media suitable for implementing thesubject matter described herein include non-transitory computer-readablemedia, such as disk memory devices, chip memory devices, programmablelogic devices, and application specific integrated circuits. Inaddition, a machine readable medium that implements the subject matterdescribed herein may be located on a single device or computing platformor may be distributed across multiple devices or computing platforms.

By way of example, a machine-readable storage medium may have one ormore instructions which when executed by a controller (such ascontroller 1414 of FIG. 14) causes the controller to: route anelectrical current through a ceramic structure; route the electricalcurrent through a first layer formed on the ceramic structure andcomprised of an electrically-conducting material that adheres to theceramic structure; and route the electrical current through a secondlayer formed on the first layer and comprised of graphite to cause atleast some carbon from the graphite to be transferred to a substrate toform a film on the substrate.

It should also be noted that, in some alternative implementations, thefunctions noted in the block may occur out of the order noted in thefigures. For example, two blocks shown in succession may, in fact, beexecuted substantially concurrently, or the blocks may sometimes beexecuted in the reverse order, depending upon the functionalityinvolved. Other steps and methods may be conceived that are equivalentin function, logic, or effect to one or more blocks, or portionsthereof, of the illustrated figures. Although various arrow types andline types may be employed in the flowchart and/or block diagrams, theyare understood not to limit the scope of the corresponding embodiments.For instance, an arrow may indicate a waiting or monitoring period ofunspecified duration between enumerated steps of the depictedembodiment.

The various features and processes described above may be usedindependently of one another, or may be combined in various ways. Allpossible combinations and sub-combinations are intended to fall withinthe scope of this disclosure. In addition, certain method, event, stateor process blocks may be omitted in some implementations. The methodsand processes described herein are also not limited to any particularsequence, and the blocks or states relating thereto can be performed inother sequences that are appropriate. For example, described tasks orevents may be performed in an order other than that specificallydisclosed, or multiple may be combined in a single block or state. Theexample tasks or events may be performed in serial, in parallel, or insome other suitable manner. Tasks or events may be added to or removedfrom the disclosed example embodiments. The example systems andcomponents described herein may be configured differently thandescribed. For example, elements may be added to, removed from, orrearranged compared to the disclosed example embodiments.

Those of skill in the art will appreciate that information and signalsmay be represented using any of a variety of different technologies andtechniques. For example, data, instructions, commands, information,signals, bits, symbols, and chips that may be referenced throughout theabove description may be represented by voltages, currents,electromagnetic waves, magnetic fields or particles, optical fields orparticles, or any combination thereof.

The word “exemplary” is used herein to mean “serving as an example,instance, or illustration.” Any aspect described herein as “exemplary”is not necessarily to be construed as preferred or advantageous overother aspects. Likewise, the term “aspects” does not require that allaspects include the discussed feature, advantage or mode of operation.

While the above descriptions contain many specific embodiments of theinvention, these should not be construed as limitations on the scope ofthe invention, but rather as examples of specific embodiments thereof.Accordingly, the scope of the invention should be determined not by theembodiments illustrated, but by the appended claims and theirequivalents. Moreover, reference throughout this specification to “oneembodiment,” “an embodiment,” or similar language means that aparticular feature, structure, or characteristic described in connectionwith the embodiment is included in at least one embodiment of thepresent disclosure. Thus, appearances of the phrases “in oneembodiment,” “in an embodiment,” and similar language throughout thisspecification may, but do not necessarily, all refer to the sameembodiment, but mean “one or more but not all embodiments” unlessexpressly specified otherwise.

Certain components (including layers, coatings, or other components)listed herein may be described as “comprising,” “made of,” “including,”or similar such terms, a material or a combination of materials. In oneaspect, each of those components may also consist of that material orthe combination of materials. In another aspect, each of thosecomponents may also consist essentially of that material or thecombination of materials.

The terminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting of the aspects. As usedherein, the singular forms “a,” “an” and “the” are intended to includethe plural forms as well (i.e., one or more), unless the context clearlyindicates otherwise. An enumerated listing of items does not imply thatany or all of the items are mutually exclusive and/or mutuallyinclusive, unless expressly specified otherwise. It will be furtherunderstood that the terms “comprises,” “comprising,” “includes”“including,” “having,” and variations thereof when used herein mean“including but not limited to” unless expressly specified otherwise.That is, these terms may specify the presence of stated features,integers, steps, operations, elements, or components, but do notpreclude the presence or addition of one or more other features,integers, steps, operations, elements, components, or groups thereof.Moreover, it is understood that the word “or” has the same meaning asthe Boolean operator “OR,” that is, it encompasses the possibilities of“either” and “both” and is not limited to “exclusive or” (“XOR”), unlessexpressly stated otherwise. It is also understood that the symbol “/”between two adjacent words has the same meaning as “or” unless expresslystated otherwise. Moreover, phrases such as “connected to,” “coupled to”or “in communication with” are not limited to direct connections unlessexpressly stated otherwise.

If used herein, the term “determining” encompasses a wide variety ofactions. For example, “determining” may include calculating, computing,processing, deriving, investigating, looking up (e.g., looking up in atable, a database or another data structure), ascertaining, and thelike. Also, “determining” may include receiving (e.g., receivinginformation), accessing (e.g., accessing data in a memory), and thelike. Also, “determining” may include resolving, selecting, choosing,establishing, and the like.

Any reference to an element herein using a designation such as “first,”“second,” and so forth does not generally limit the quantity or order ofthose elements. Rather, these designations may be used herein as aconvenient method of distinguishing between two or more elements orinstances of an element. Thus, a reference to first and second elementsdoes not mean that only two elements may be used there or that the firstelement must precede the second element in some manner. Also, unlessstated otherwise a set of elements may include one or more elements. Inaddition, terminology of the form “at least one of A, B, or C” or “A, B,C, or any combination thereof” used in the description or the claimsmeans “A or B or C or any combination of these elements.” For example,this terminology may include A, or B, or C, or A and B, or A and C, or Aand B and C, or 2A, or 2B, or 2C, or 2A and B, and so on. As a furtherexample, “at least one of: A, B, or C” is intended to cover A, B, C,A-B, A-C, B-C, and A-B-C, as well as multiples of the same members(e.g., any lists that include AA, BB, or CC). Likewise, “at least oneof: A, B, and C” is intended to cover A, B, C, A-B, A-C, B-C, and A-B-C,as well as multiples of the same members. Similarly, as used herein, aphrase referring to a list of items linked with “and/or” refers to anycombination of the items. As an example, “A and/or B” is intended tocover A alone, B alone, or A and B together. As another example, “A, Band/or C” is intended to cover A alone, B alone, C alone, A and Btogether, A and C together, B and C together, or A, B, and C together.

What is claimed is:
 1. A method for forming a film, the methodcomprising: passing an electrical current through a ceramic structurecomprising a cylindrical tube; passing the electrical current through abase layer formed on an inner-facing surface and on an outer-facingsurface of the cylindrical tube and comprised of a metallic coating thatadheres to the ceramic structure; and passing the electrical currentthrough an outer layer formed on an inner-facing surface and on anouter-facing surface of the base layer and comprised of carbon to causeat least some of the carbon to be transferred to a device to form a filmon the device.
 2. The method of claim 1, wherein the metallic coatingcomprises a silver-containing coating.
 3. The method of claim 2, whereinthe silver-containing coating comprises silver flakes with a D50particle size of less than twenty microns.
 4. The method of claim 2,wherein the silver-containing coating has a volume resistivity of about0.0002 ohm-cm at room temperature.
 5. The method of claim 1, wherein themetallic coating comprises metal flakes.
 6. The method of claim 1,wherein a metal of the metallic coating is selected from a groupconsisting of one or more of silver, nickel, copper and gold.
 7. Themethod of claim 1, wherein the metallic coating is formed of materialsselected to withstand cathodic-arc deposition temperatures of at least500° F.
 8. The method of claim 1, wherein the film that is formed is adiamond-like carbon (DLC) film.
 9. A method for forming a cathodestructure for use in a deposition apparatus, the method comprising:providing a ceramic structure comprising a cylindrical tube; providing afirst layer on an inner-facing surface and on an outer-facing surface ofthe cylindrical tube of the ceramic structure and comprising a metalliccoating that adheres to the ceramic structure; and providing anelectrically-conducting second layer formed on an inner-facing surfaceand on an outer-facing surface of the first layer and comprising carbon.10. The method of claim 9, wherein the providing the first layer on theinner-facing surface and on the outer-facing surface of the cylindricaltube of the ceramic structure comprises: applying the first layer to theinner-facing surface and to the outer-facing surface of the cylindricaltube of the ceramic structure; and applying first heat to the ceramicstructure at a preselected temperature and for a preselected duration,wherein the preselected temperature and the preselected duration arepredetermined for a preselected contact resistance of the first layer.11. The method of claim 10, further comprising: applying a graphiticpaint to the ceramic structure after the applying first heat; andapplying second heat to the ceramic structure with the graphitic paintfor a preselected temperature and for a preselected duration.
 12. Themethod of claim 11, further comprising: applying third heat to theceramic structure with the graphitic paint for a preselected temperatureand for a preselected duration, wherein the preselected temperature andthe preselected duration of the applying third heat are predeterminedfor a preselected contact resistance of the graphitic paint.
 13. Themethod of claim 9, wherein the metallic coating comprises asilver-containing coating.
 14. The method of claim 13, wherein thesilver-containing coating comprises silver flakes with a D50 particlesize of less than twenty microns.
 15. The method of claim 13, whereinthe silver-containing coating has a volume resistivity of about 0.0002ohm-cm at room temperature.
 16. The method of claim 9, wherein a metalof the metallic coating is selected from a group consisting of silver,nickel, copper and gold.
 17. The method of claim 9, wherein the metalliccoating comprises metal flakes.